Components having vibration dampers enclosed therein and methods of forming such components

ABSTRACT

A component formed by an additive manufacturing process includes a body and a first vibration damper. The body is formed from an additive manufacturing material, and defines at least a first cavity completely enclosed within the body. The first vibration damper is disposed within the first cavity. The first vibration damper includes a flowable medium and a first solidified element formed from the additive manufacturing material. The flowable medium surrounds the first solidified element.

BACKGROUND

The field of the disclosure relates generally to vibration dampers and,more particularly, to components having vibration dampers enclosedtherein, and methods of forming such components.

Vibration of mechanical components may induce component fatigue andexcessive localized noise within mechanical systems, such as gas turbineengines. Accordingly, reducing vibrational loading of mechanicalcomponents within such mechanical systems is a priority among producersand users of such systems.

At least some known attempts to reduce vibrational loading of mechanicalcomponents include incorporating particle-filled cavities within themechanical components.

However, such known particle-Idled cavities incorporated into mechanicalcomponents generally do not reduce vibrational loading of suchcomponents to a satisfactory level. Moreover, fabrication of suchcomponents generally requires separate steps for forming the cavities,evacuating the cavities, and re-filling the cavities withparticle-damping powders. Further, because the cavities must beaccessible after the component is formed in order to evacuate andre-fill the cavities, the locations at which particle-filled cavitiesmay be formed within mechanical components are limited.

BRIEF DESCRIPTION

In one aspect, a component formed by an additive manufacturing processis provided. The component includes a body formed from an additivemanufacturing material, and a first vibration damper. The body definesat least a first cavity completely enclosed within the body. Thevibration damper is disposed within the first cavity. The vibrationdamper includes a flowable medium and a first solidified element formedfrom the additive manufacturing material. The flowable medium surroundsthe first solidified element.

In another aspect, a gas turbine engine is provided. The gas turbineengine includes a combustor assembly, a turbine assembly, and acompressor assembly. The combustor assembly includes a plurality of fuelmixers. The turbine assembly includes a plurality of turbine blades. Thecompressor assembly includes a plurality of fan blades. At least one ofthe combustor assembly, fuel mixers, turbine blades, and fan bladesinclude a component formed by an additive manufacturing process. Thecomponent includes a body formed from an additive manufacturingmaterial, and a first vibration damper. The body defines at least afirst cavity completely enclosed within the body. The vibration damperis disposed within the first cavity. The vibration damper includes aflowable medium and a first solidified element formed from the additivemanufacturing material. The flowable medium surrounds the firstsolidified element.

In yet another aspect, a method of forming a component by an additivemanufacturing process is provided. The method includes forming a body ofthe component from an additive manufacturing material, forming a firstcavity within the body, and forming a first vibration damper within thefirst cavity. Forming a first vibration damper within the first cavityincludes forming a first solidified element by selectively solidifyingthe additive manufacturing material, and enclosing the first solidifiedelement and a flowable medium within the first cavity.

DRAWINGS

These and other features, aspects, and advantages of the presentdisclosure will become better understood when the following detaileddescription is read with reference to the accompanying drawings in whichlike characters represent like parts throughout the drawings, wherein:

FIG. 1 is a schematic illustration of an exemplary gas turbine engine;

FIG. 2 is a partial cross-section of an exemplary component of the gasturbine engine shown in FIG. 1;

FIG. 3 is a partial cross-section of an exemplary alternative componentsuitable for use in the gas turbine engine shown in FIG. 1; and

FIG. 4 is a flowchart of an exemplary method of forming a component byan additive manufacturing process.

Unless otherwise indicated, the drawings provided herein are meant toillustrate features of embodiments of the disclosure. These features arebelieved to be applicable in a wide variety of systems comprising one ormore embodiments of the disclosure. As such, the drawings are not meantto include all conventional features known by those of ordinary skill inthe art to be required for the practice of the embodiments disclosedherein.

DETAILED DESCRIPTION

In the following specification and the claims, reference will be made toa number of terms, which shall be defined to have the followingmeanings.

The singular forms “a”, “an”, and “the” include plural references unlessthe context clearly dictates otherwise.

Approximating language, as used herein throughout the specification andclaims, may be applied to modify any quantitative representation thatcould permissibly vary without resulting in a change in the basicfunction to which it is related. Accordingly, a value modified by a termor terms, such as “about” and “substantially”, are not to be limited tothe precise value specified. In at least some instances, theapproximating language may correspond to the precision of an instrumentfor measuring the value. Here and throughout the specification andclaims, range limitations may be combined and/or interchanged, suchranges are identified and include all the sub-ranges contained thereinunless context or language indicates otherwise.

The components, systems, and methods described herein enable efficientuse of additive manufacturing technology to form vibration damperswithin components. Specifically, the components, systems, and methodsdescribed herein take advantage of the additive nature of additivemanufacturing processes by strategically capturing, and enclosingunsolidified additive manufacturing material and/or solidifiedelement(s) within one or more cavities formed in the component duringthe additive manufacturing process. The vibration dampers may beprecisely formed and strategically positioned within the component so asto not compromise the structural integrity of the component. Further,through use of additive manufacturing technology, the components,systems, and methods described herein enable formation of particlevibration dampers at locations within the component that are otherwiseinaccessible. Therefore, in contrast to known articles and methods ofmanufacturing such articles, the components, systems, and methodsdescribed herein facilitate fabrication of components having vibrationdampers enclosed therein, and provide improved damping performance overknown articles.

FIG. 1 is a schematic illustration of an exemplary gas turbine engine,indicated generally at 100. In the exemplary embodiment, gas turbineengine 100 includes a combustor assembly 102, a low-pressure turbineassembly 104 and a high-pressure turbine assembly 106, collectivelyreferred to as turbine assemblies 104 and 106, Gas turbine engine 100also includes a low-pressure compressor assembly 108 and a high-pressurecompressor assembly 110, generally referred to as compressor assemblies108 and 110. In the exemplary embodiment, gas turbine engine 100 is anaircraft engine, although in alternative embodiments, gas turbine engine100 may be any other suitable gas turbine engine, such as an electricpower generation gas turbine engine or a land-based gas turbine engine.

Low-pressure compressor assembly 108 and high-pressure compressorassembly 110 each include a plurality of fan blades 112 and 114,respectively, for compressing ambient air flowing into gas turbineengine 100. Combustor assembly 102 includes a plurality of fuel mixers116 for mixing fuel with pressurized air and/or injecting foci or anair/fuel mixture into a combustion chamber 118. Low-pressure turbineassembly 104 and high-pressure turbine assembly 106 each include aplurality of turbine blades 120 and 122, respectively.

In operation, ambient air, represented by arrow 124, enters gas turbineengine 100 and is pressurized by low-pressure compressor assembly 108and/or high-pressure compressor assembly 110. Pressurized air,represented by arrow 126, is mixed with fuel via fuel mixers 116, andcombusted within combustion chamber 118, producing high-energycombustion products, represented by arrow 128. Combustion products 128flow from combustion chamber 118 to high-pressure turbine assembly 106and drive high-pressure compressor assembly 110 via a first drive shaft130. Combustion products 128 then flow to low-pressure turbine assembly104 and drive low-pressure compressor assembly 108 via a second driveshaft 132. Combustion products 128 exit gas turbine engine 100 throughan exhaust nozzle 134, and provide at least a portion of the jetpropulsive thrust of the gas turbine engine 100.

The components of gas turbine engine 100 may be subjected to vibrationalforces during operation, resulting in part from rotation of compressorassemblies 108 and 110 and turbine assemblies 104 and 106, and thecombustion of gases within gas turbine engine 100.

FIG. 2 is a partial cross-section of an exemplary component 200 of gasturbine engine 100. In the exemplary embodiment, component 200 is aturbine blade 120, in particular, a hollow turbine blade, although inalternative embodiments, component 200 may be any other component of gasturbine engine 100, such as fan blades 112 and 114 or fuel mixer 116, inyet further alternative embodiments, component 200 may be a componentother than a component of a gas turbine engine 100.

In the exemplary embodiment, component 200 is fabricated by a selectivelaser sintering (SLS) process, although any other suitable additivemanufacturing process (also known as rapid prototyping, rapidmanufacturing, and 3D printing) may be used to fabricate component 200,such as direct metal laser sintering (DMLS), electron beam melting(EBM), selective heat sintering (SHS), or stereolithography (SLA).Component 200 may be fabricated from any suitable additive manufacturingmaterial, such as metal powder(s) (e.g., cobalt chrome, steels,aluminum, titanium and/or nickel alloys), gas atomized metal powder(s),thermoplastic powder(s) (e.g., polylactic acid (PLA), acrylonitrilebutadiene styrene (ABS), and/or high-density polyethylene (HDPE)),photopolymer resin(s) (e.g., UV-curable photopolymers), thermosetresin(s), thermoplastic resin(s), or any other suitable material thatenables component 200 to function as described herein. As used herein,the term “additive manufacturing material” includes any materials thatmay be used to fabricate a component by an additive manufacturingprocess, such as the additive manufacturing processes described above.

Component 200 includes a first cavity 202 and a second cavity 204, eachdefined within a body 206 of component 200. First cavity 202 and secondcavity 204 are each defined by one or more cavity walls 208, and arecompletely enclosed within body 206 of component 200. In alternativeembodiments, one or more cavities 202 and 204 may be only partiallyenclosed within body 206. In the exemplary embodiment, component 200includes a total of two cavities 202 and 204, although component 200 mayinclude any suitable number of cavities 202 and 204 that enablescomponent 200 to function as described herein. Further, in the exemplaryembodiment, first cavity 202 and second cavity 204 each have a generallyrectangular shape, although in alternative embodiments, first cavity 202and second cavity 204 may have any suitable shape that enables component200 to function as described herein.

First cavity 202 includes a vibration damper 210 enclosed therein.Vibration damper 210 includes a solidified element 212 and a flowablemedium 214, in operation, vibrational energy traveling through component200 causes solidified element 212 and flowable medium 214 to interactand collide with one another, resulting in kinetic and/or frictionaldamping of vibrational energy.

In the exemplary embodiment, solidified element 212 is fabricated duringthe same additive manufacturing process used to fabricate component 200.Thus, solidified element 212 may be fabricated from the same additivemanufacturing material used to fabricate component 200. In alternativeembodiments, solidified element 212 may be fabricated from a materialother than the additive manufacturing material used to fabricatecomponent 200. Also in the exemplary embodiment, flowable medium 214 isunsolidified additive manufacturing material, i.e., additivemanufacturing material that was not solidified during the fabrication ofcomponent 200. Thus, depending upon the additive manufacturing processused to fabricate component 200, flowable medium 214 may be a liquidand/or a solid. In alternative embodiments, flowable medium 214 mayinclude materials other than unsolidified additive manufacturingmaterial. For example, flowable materials other than the additivemanufacturing material may be added to first cavity 202 during thefabrication of component 200.

In the exemplary embodiment, solidified element 212 is shapedsubstantially complementary to first cavity 202 (i.e., generallyrectangularly), although in alternative embodiments, solidified element212 may have any suitable shape that enables vibration damper 210 tofunction as described herein. In some embodiments, solidified element212 may have a relatively high surface area to volume ratio to increasefrictional damping. For example, the surface of solidified element 212may be non-planar, jagged, or textured to increase the surface area tovolume ratio of solidified element 212.

In the exemplary embodiment, solidified element 212 and flowable medium214 occupy at least about 95% of the volume enclosed by first cavity 202and, more particularly, at least about 98% of the volume enclosed byfirst cavity 202. In alternative embodiments, solidified element 212 andflowable medium 214 may occupy less than about 95% of the volumeenclosed by first cavity 202. In yet further alternative embodiments,before first cavity 202 is completely formed during the additivemanufacturing process, some of the unsolidified additive manufacturingmaterial remaining in first cavity 202 may be removed such thatsolidified element 212 and flowable medium 214 occupy less thansubstantially the entire volume enclosed by first cavity 202.

In the exemplary embodiment, solidified element 212 occupiesapproximately 80% of the volume enclosed by first cavity 202, andflowable medium 214 occupies a range of between about 10-20% of thevolume enclosed by first cavity 202. In alternative embodiments, therelative volumes occupied by solidified element 212 and flowable medium214 may vary. For example, the size of solidified element 212 may varysuch that solidified element 212 occupies a range of between about 20%and about 90% of the volume enclosed by first cavity 202, and morespecifically, between about 50% to about 80% of the volume enclosed byfirst cavity 202. The amount of flowable medium 214 enclosed withinfirst cavity 202 may also vary (for example, by removing unsolidifiedadditive manufacturing material during the fabrication process) suchthat flowable medium 214 occupies a range of between about 5% and about100% of the volume enclosed by first cavity 202, and more specifically,between about 20% to about 50% of the volume enclosed by first cavity202.

Solidified element 212 of vibration damper 210 is mechanically detachedfrom cavity walls 208, and is at least partially suspended by flowablemedium 214. Second cavity 204 includes a vibration damper 216substantially similar to vibration damper 210, except that solidifiedelement 212 of vibration damper 216 is mechanically coupled to cavitywall 208 via a connecting element 218. Connecting element 218 may beconfigured to be detached from cavity wall 208 and/or solidified element212 after solidified element 212 is partially formed. For example, toenable solidified element 212 to be completely suspended by flowablemedium 214, connecting element 218 may be structurally weak and/orunstable such that connecting element 218 may be detached from cavitywall 208 and/or solidified element 212 during post-fabricationprocessing and/or during normal use of component 200. Alternatively,connecting element 218 may be configured to be permanently coupled tosolidified element 212 and cavity wall 208 such that connecting element218 is part of vibration damper 216.

In the exemplary embodiment, solidified element 212 of vibrationdampener 216 is mechanically coupled to cavity wall 208 at a singlepoint along the cavity wall 208, although in alternative embodiments,solidified element 212 may be mechanically coupled to cavity wall 206 atany suitable number of points along cavity wall 208 that enablesvibration damper 216 to function as described herein. In embodimentswhere connecting element 218 is configured to be detached from cavitywall 208 and/or solidified element 212, solidified element 212 may bemechanically coupled to cavity wall 208 at no more than two points alongcavity wall 208.

In the exemplary embodiment, vibration dampers 210 and 216 each includea single solidified element 212 although in alternative embodiments, oneor both vibration dampers 210 and 216 may include more than onesolidified element 212. For example, one or more vibration dampers 210and 216 may include two or more distinct solidified elements 212disposed within a respective cavity 202 and 204.

FIG. 3 is a partial cross-section of an exemplary alternative component300 suitable for use in gas turbine engine 100. Component 300 issubstantially identical to component 200 (shown in FIG. 2), with theexception that component 300 includes secondary vibration dampers 302and 304 in addition to primary vibration dampers 306 and 308. As such,elements shown in FIG. 3 are labeled with the same reference numbersused in FIG. 2.

Primary vibration dampers 306 and 308 are substantially identical tovibration dampers 210 and 216, with the exception that primary vibrationdampers 306, 308 include secondary vibration dampers 302 and 304. Asshown in FIG. 3, solidified elements 212 of each primary vibrationdamper 306 and 308 define third and fourth cavities 310 and 312completely enclosed within the respective solidified element 212. Thirdand fourth cavities 310 and 312 each include a secondary vibrationdamper 302 and 304 disposed therein. Secondary vibration dampers 302 and304 may have configurations substantially similar to vibration dampers210 and 216 (shown in FIG. 2) and/or primary vibration dampers 306 and308 and/or may include any of the features of vibration dampers 210 and216 described above with reference to FIG. 2 and/or any of the featuresof primary vibration dampers 306 and 308 described herein. For example,each secondary vibration damper 302 and 304 includes a second solidifiedelement 314 and a second flowable medium 316. Further, second solidifiedelement 314 of secondary vibration damper 304 is mechanically coupled toa cavity wall 318 of fourth cavity 312 by a connecting element 320substantially similar to connecting element 218.

FIG. 4 is a flowchart of an exemplary method of forming a component byan additive manufacturing process. In the exemplary method, vibrationdampers 210, 216, 302, 304, 306, and 308 are advantageously formedin-situ dining the additive manufacturing: process used to fabricatecomponents 200 and 300. Specifically, referring to FIG. 4, an exemplarymethod of forming a component, such as component 200 (shown in FIG. 2)or component 300 (shown in FIG. 3), is indicated generally at 400. Abody of the component is formed 402 from an additive manufacturingmaterial, such as metal powder(s) (e.g., cobalt, iron, aluminum,titanium and/or nickel alloys), gas atomized metal powder(s),thermoplastic powder(s), photopolymer resin(s), thermoset resin(s), orthermoplastic resin(s). A first cavity is formed 404 within the body. Afirst vibration damper is formed. 406 within the first cavity by forminga first solidified element by selectively solidifying the additivemanufacturing material, and enclosing the first solidified element and aflowable medium within the first cavity. The first vibration damper maybe formed such that the first vibration damper is shaped substantiallycomplementary to the first cavity.

In one embodiment, a connecting element is formed 408 between a cavitywall of the first cavity and the first solidified element to support thefirst solidified element during the fabrication process. The firstsolidified element may be detached 410 from the connecting element afterthe first solidified element is at least partially formed. Optionally,the first solidified element may be detached from the connecting elementafter the first cavity is formed (e.g., through normal use of thecomponent or through post-fabrication processing). Additionally oralternatively, a non-detachable connecting element may be formed betweena cavity wall of the first cavity and the first solidified element.

When forming the first cavity and/or when forming the first vibrationdamper within the first cavity, unsolidified additive manufacturingmaterial may be enclosed 412 within first cavity to act as a flowablemedium of the first vibration damper by leaving the unsolidifiedmanufacturing material within the first cavity (i.e., by not removingthe unsolidified manufacturing material). Alternatively, other materialsmay be enclosed within first cavity to act as a flowable medium byadding other materials to the first cavity before the first cavity iscompletely formed, or enclosed.

Forming the first vibration damper includes forming 414 a secondsolidified element by selectively solidifying the additive manufacturingmaterial, and enclosing 416 the second solidified element within thefirst cavity. Additionally or alternatively, a second cavity may beformed 418 within one or more of the first and second solidifiedelements, and a second vibration damper may be formed 420 within thesecond cavity.

The above described components, systems, and methods enable efficientuse of additive manufacturing technology to form vibration damperswithin components. Specifically, the components, systems, and methodsdescribed herein take advantage of the additive nature of additivemanufacturing processes by strategically capturing and enclosingunsolidified additive manufacturing material and/or solidified elements)within one or more cavities formed in the component during the additivemanufacturing process. The vibration dampers may be precisely formed andstrategically positioned within the component so as to not compromisethe structural integrity of the component. Further, through use ofadditive manufacturing technology, the components, systems, and methodsdescribed herein enable formation of particle vibration dampers atlocations within the component that are otherwise inaccessible.Therefore, in contrast to known articles and methods of manufacturingsuch articles, the components, systems, and methods described hereinenable faster, more efficient fabrication of components having vibrationdampers enclosed therein, and provide improved clamping performance overknown articles.

An exemplary technical effect of the systems and methods describedherein includes at least one of: (a) improving the vibration dampingperformance of components fabricated using additive manufacturingprocesses; and (b) reducing the amount of time and costs needed tofabricate components having vibration dampers enclosed therein.

Although specific features of various embodiments of the invention maybe shown in some drawings and not in others, this is for convenienceonly. In accordance with the principles of the invention, any feature ofa drawing may be referenced and/or claimed in combination with anyfeature of any other drawing.

This written description uses examples to disclose the invention,including the best mode, and also to enable any person skilled in theart to practice the invention, including making and using any devices orsystems and performing any incorporated methods. The patentable scope ofthe invention is defined by the claims, and may include other examplesthat occur to those skilled in the art. Such other examples are intendedto be within the scope of the claims if they have structural elementsthat do not differ from the literal language of the claims, or if theyinclude equivalent structural elements with insubstantial differencesfrom the literal language of the claims.

What is claimed is:
 1. A component formed by an additive manufacturingprocess, said component comprising: a body formed from an additivemanufacturing material, said body defining at least a first cavitycompletely enclosed within said body and a second cavity completelyenclosed within said body; a first vibration damper disposed within saidfirst cavity, said first vibration damper comprising: a first flowablemedium; and a first solidified element formed from the additivemanufacturing material, wherein said first flowable medium surroundssaid first solidified element and wherein said first solidified elementis mechanically detached from said body and at least partially suspendedby said first flowable medium; and a second vibration damper disposedwithin said second cavity, said second vibration damper comprising: asecond flowable medium; a second solidified element formed from theadditive manufacturing material, wherein said second flowable mediumsurrounds said second solidified element; and a connecting elementcoupling the second solidified element to a cavity wall of the secondcavity.
 2. The component in accordance with claim 1, wherein said firstand/or second solidified element is shaped substantially complementaryto said first cavity.
 3. The component in accordance with claim 1,wherein said first vibration damper further comprises an additionalsolidified element formed from the additive manufacturing material, saidflowable medium surrounding said second additional solidified element.4. The component in accordance with claim 1, wherein said first and/orsecond cavity has a volume enclosed therein, and wherein said firstsolidified element and said flowable medium occupy at least about 95% ofthe volume enclosed by said first cavity.
 5. The component in accordancewith claim 1, wherein said first and/or second flowable medium comprisesunsolidified additive manufacturing material.
 6. The component inaccordance with claim 1, wherein said additive manufacturing materialcomprises one of a metal powder, a thermoplastic powder, a photopolymerresin, a thermoset resin, a thermoplastic resin, or combinationsthereof.
 7. A gas turbine engine comprising: a combustor assemblyincluding a plurality of fuel mixers; a turbine assembly including aplurality of turbine blades; and a compressor assembly including aplurality of fan blades, at least one of said combustor assembly, fuelmixers, turbine blades, and fan blades comprising a component formedaccording to claim
 1. 8. The gas turbine engine in accordance with claim7, wherein said first solidified element is shaped substantiallycomplementary to said first cavity.
 9. The gas turbine engine inaccordance with claim 7, wherein said first vibration damper furthercomprises an additional solidified element formed from the additivemanufacturing material, said first flowable medium surrounding saidsecond additional solidified element.
 10. The gas turbine engine inaccordance with claim 7, wherein said first cavity has a volume enclosedtherein, and wherein said first solidified element and said firstflowable medium occupy at least about 95% of the volume enclosed by saidfirst cavity.
 11. The gas turbine engine in accordance with claim 7,wherein said first flowable medium comprises unsolidified additivemanufacturing material.
 12. The gas turbine engine in accordance withclaim 7, wherein said additive manufacturing material comprises one of ametal powder, a thermoplastic powder, a photopolymer resin, a thermosetresin, a thermoplastic resin, or combinations thereof.
 13. The componentin accordance with claim 1, wherein said first cavity has a volumeenclosed therein, and wherein the first solidified element occupies arange of between about 20% and about 90% of the volume enclosed by thefirst cavity.
 14. The component in accordance with claim 13, wherein thefirst solidified element occupies a range of between about 50% and about80% of the volume enclosed by the first cavity.
 15. The component inaccordance with claim 13, wherein the first flowable medium occupies arange of between about 20% to about 50% of the volume enclosed by thefirst cavity.
 16. The component in accordance with claim 1, wherein saidconnecting element is configured to be mechanically detached from atleast one of the cavity wall or the second solidified element.